Multi-fiber ferrule-less duplex fiber optic connectors with multi-fiber alignment devices

ABSTRACT

Aspects and techniques of the present disclosure relate to an alignment device that includes a groove-type alignment structure with a support region for receiving an optical fiber inserted along a fiber insertion axis. The optical fiber has a first side and a second, opposite side. The groove-type alignment structure engages the first side of the optical fiber. The alignment device includes a stabilization structure that engages the first side of the optical fiber and a first angled transition surface that engages the second, opposite side of the optical fiber. The present disclosure also relates to an alignment system that includes a first housing piece; a second housing piece adapted to mate with the first housing piece; and a flat structure positioned between the first and second housing pieces.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.16/466,766, filed on Jun. 5, 2019, which is a National Stage Applicationof PCT/US2017/064671, filed on Dec. 5, 2017, which claims the benefit ofU.S. Patent Application Ser. No. 62/430,343, filed on Dec. 5, 2016, andclaims the benefit of U.S. Patent Application Ser. No. 62/565,323, filedon Sep. 29, 2017, the disclosures of which are incorporated herein byreference in their entireties. To the extent appropriate, a claim ofpriority is made to each of the above disclosed applications.

TECHNICAL FIELD

The present disclosure relates generally to fiber optic connectors. Moreparticularly, the present disclosure relates to ferrule-less fiber opticconnectors with alignment devices.

BACKGROUND

Fiber optic communication systems are becoming prevalent in part becauseservice providers want to deliver high bandwidth communicationcapabilities (e.g., data and voice) to customers. Fiber opticcommunication systems employ a network of fiber optic cables to transmitlarge volumes of data and voice signals over relatively long distances.Optical fiber connectors are an important part of most fiber opticcommunication systems. Fiber optic connectors allow two optical fibersto be quickly optically connected without requiring a splice. Fiberoptic connectors can be used to optically interconnect two lengths ofoptical fiber. Fiber optic connectors can also be used to interconnectlengths of optical fiber to passive and active equipment.

A typical fiber optic connector includes a ferrule assembly supported ata distal end of a connector housing. A spring is used to bias theferrule assembly in a distal direction relative to the connectorhousing. The ferrule functions to support an end portion of at least oneoptical fiber (in the case of a multi-fiber ferrule, the ends ofmultiple fibers are supported). The ferrule has a distal end face atwhich a polished end of the optical fiber is located. When two fiberoptic connectors are interconnected, the distal end faces of theferrules abut one another and the ferrules are forced proximallyrelative to their respective connector housings against the bias oftheir respective springs. With the fiber optic connectors connected,their respective optical fibers are coaxially aligned such that the endfaces of the optical fibers directly oppose one another. In this way, anoptical signal can be transmitted from optical fiber to optical fiberthrough the aligned end faces of the optical fibers. For many fiberoptic connector styles (LC, SC, MPO), alignment between two fiber opticconnectors is provided through the use of an intermediate fiber opticadapter.

Another type of fiber optic connector can be referred to as aferrule-less fiber optic connector. In a ferrule-less fiber opticconnector, an end portion of an optical fiber corresponding to theferrule-less fiber optic connector is not supported by a ferrule.Instead, the end portion of the optical fiber is a free end portion.Similar to the ferruled connectors described above, fiber optic adapterscan be used to assist in optically coupling together two ferrule-lessfiber optic connectors. Example ferrule-less fiber optic connectors aredisclosed by PCT Publication No. WO 2012/112344; PCT Publication No. WO2013/117598; and U.S. Pat. No. 8,870,466.

Fiber optical adapters are used to optically couple together opticalfiber tips of optical connectors. Fiber optical adapters can includespecialized fiber alignment devices to receive bare optical fibers andalign the fiber tips to enable the transfer of optical signalstherebetween. Optical connectors can be secured to the optical adapterswhen received at the ports of the optical adapters. Improvements areneeded in the area of fiber alignment for multi-fiber fiber opticconnectors.

SUMMARY

One aspect of the present disclosure relates to a fiber alignmentdevice. Although a multi-fiber alignment device is described herein, theadvantages and features of the present disclosure can also relate to asingle fiber alignment device.

The fiber alignment device can include a first fixed sized hole thatdefines a first passage extending along a fiber insertion axis toreceive a first optical fiber. The fiber alignment device includes aplurality of projections that extend from an interior surface of thefirst fixed sized hole. The plurality of projections can define debriscollection regions therebetween.

Another aspect of the present disclosure relates to a fiber alignmentdevice for optically coupling first and second optical fibers. The fiberalignment device can include a first fixed sized hole defining a firstpassage that extends along a fiber insertion axis for receiving thefirst optical fiber; a second fixed sized hole defining a second passagefor receiving the second optical fiber. The second passage can bealigned along the fiber insertion axis and be co-axial with the firstpassage. The fiber alignment device can also include a cavity regionthat forms a gap separating the first and second passages, and ends ofthe first and second optical fibers meet and are co-axially aligned atthe cavity region.

Another aspect of the present disclosure relates to a fiber alignmentdevice for optically coupling first and second optical fibers. The fiberalignment device can include a first hole defining a first passage thatextends along a fiber insertion axis for receiving the first opticalfiber; a second hole defining a second passage for receiving the secondoptical fiber. The second passage can be aligned along the fiberinsertion axis and be co-axial with the first passage. The first andsecond passages can have open sides, the first and second passages caninclude hole-defining portions that have circular curvatures, thehole-defining portions can be moveable between a first position wherethe hole-defining portions define a first diameter and a second positionwhere the hole-defining portions define a second diameter. The firstdiameter can be larger than the second diameter.

Another aspect of the present disclosure relates to a fiber alignmentdevice for optically coupling first and second optical fiber. The fiberalignment device can include a first hole defining a first passage thatextends along a fiber insertion axis for receiving the first opticalfiber; a second hole defining a second passage for receiving the secondoptical fiber. The second passage can be aligned along the fiberinsertion axis and be co-axial with the first passage. The first andsecond passages can have open sides. The first and second passages caninclude hole-defining portions that can be moveable between a firstposition where the hole-defining portions define a first diameter alongat least a majority of lengths of the first and second passages, and asecond position where the hole-defining portions define a seconddiameter along at least a majority of the lengths of the first andsecond passages. The first diameter can be larger than the seconddiameter.

A further aspect of the present disclosure relates to a multi-fiberalignment device. The multi-fiber alignment device can include a basemember; a first flexible jaw flange that cooperates with the base memberto define a first split-sleeve; a second flexible jaw flange thatcooperates with the base member to define a second split-sleeve that isco-axially aligned with the first split-sleeve. The first and secondflexible jaw flanges can be moveable between an alignment position and anon-alignment position. When the first and second flexible jaw flangesare in the non-alignment position, the first and second split-sleevesare opened to allow for insertion of an optical fiber. When the firstand second flexible jaw flanges are in the alignment position, the firstand second split-sleeves are closed to tighten down on fiber cladding ofoptical fibers to lock optical fibers independently in the first andsecond split-sleeves, respectively.

Another aspect of the present disclosure relates to an alignment devicethat can include an alignment body; a first fixed sized hole that can bedefined in the alignment body, the first fixed sized hole defining afirst passage that extends along a fiber insertion axis to receive afirst optical fiber; and a second fixed sized hole that can be definedin the alignment body. The second fixed sized hole defining a secondpassage that can extend along the fiber insertion axis to receive asecond optical fiber. The first and second passages can be co-axiallyaligned. Where the alignment device does not include any structureassociated with the first and second fixed sized holes that deflectsupon insertion of the first and second optical fibers.

Another aspect of the present disclosure relates to a fiber opticconnector. The fiber optic connector can include a connector body havinga front end and an opposite rear end. The connector body defining alongitudinal axis that extends through the connector body in anorientation that extends from the front end to the rear end of theconnector body. The fiber optic connector can include at least oneoptical fiber that extends through the connector body from the rear endto the front end. The optical fiber can have a fiber end accessible atthe front end of the connector body. A retractable nose piece can bemounted at the front end of the connector body. The retractable nosepiece defining a fiber passage through which the optical fiber extends.The retractable nose piece can be movable along the longitudinal axisbetween an extended position where a front end portion of the opticalfiber is protected within the fiber passages and a retracted positionwhere the front end portion of the optical fiber projects forwardlybeyond the retractable nose piece. The fiber optic connector can includea cavity defined in the retractable nose piece and configured to receivea fiber tip of the optical fiber when the nose piece is not retracted.The cavity can contain gel for encapsulating the fiber tip.

A further aspect of the present disclosure relates to an alignmentsystem that includes a first housing piece; a second housing pieceadapted to mate with the first housing piece; a groove-type alignmentstructure; and a plate that includes a plurality of elastic members thatcooperates with the groove-type alignment structure. The plate can bepositioned between the first and second housing pieces.

A further aspect of the present disclosure relates to an alignmentsystem that includes a first housing piece; a second housing pieceadapted to mate with the first housing piece; and a flat structurepositioned between the first and second housing pieces.

Another aspect of the present disclosure relates to an alignment devicethat includes a groove-type alignment structure that has a supportregion for receiving an optical fiber inserted along a fiber insertionaxis, the optical fiber has a first side and a second, opposite side.The groove-type alignment structure engages the first side of theoptical fiber. The alignment device includes a stabilization structurethat engages the first side of the optical fiber and a first angledtransition surface that engages the second, opposite side of the opticalfiber.

A further aspect of the present disclosure relates to a fiber alignmentdevice for receiving an optical fiber of a ferrule-less fiber opticconnector. The optical fiber can include a first side and an oppositesecond side. The fiber alignment device can include: a first piece thatdefines a fiber deflection structure; a second piece that includes agroove-type fiber alignment structure and a fiber stabilizationstructure that each face in an opposing direction as compared to thefiber deflection structure; and a fiber path for receiving the opticalfiber. The fiber path can be defined between the first and secondpieces, where the fiber path can include a first fiber contact locationprovided by the groove-type fiber alignment structure, a second fibercontact location provided by the fiber deflection structure, and a thirdfiber contact location provided by the fiber stabilization structure.The first fiber contact location can be spaced from the third fibercontact location in an orientation along the fiber path, and the secondfiber contact location can be positioned between the first and thirdfiber contact locations in the orientation along the fiber path. Whenthe optical fiber has been fully inserted along the fiber path: a) thefirst side of the optical fiber contacts the second fiber contactlocation causing the optical fiber to be deflected such that the secondside of the optical fiber comes into contact with the first fibercontact location and the third fiber contact location; and b) theoptical fiber is flexed between the first and third fiber contactlocations by engagement with the second fiber contact location. Theinherent elasticity of the flexed optical fiber causes an end portion ofthe optical fiber to be biased within the groove-type fiber alignmentstructure at the first fiber contact location.

A variety of additional aspects will be set forth in the descriptionthat follows. The aspects relate to individual features and tocombinations of features. It is to be understood that both the foregoinggeneral description and the following detailed description are exemplaryand explanatory only and are not restrictive of the broad inventiveconcepts upon which the embodiments disclosed herein are based.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the description, illustrate several aspects of the presentdisclosure. A brief description of the drawings is as follows:

FIG. 1 illustrates a prior art ferrule-less fiber optic connector;

FIG. 2 illustrates a prior art fiber optic adapter compatible with theferrule-less fiber optic connector of FIG. 1;

FIG. 3 illustrates a ferrule-less fiber optic connection system inaccordance with the principles of the present disclosure, the systemshows two duplex fiber optic connectors positioned within anintermediate fiber optic adapter for mating the duplex fiber opticconnectors with another duplex fiber optic connector; in accordance withthe principles of the present disclosure;

FIG. 4 illustrates the duplex fiber optic connectors shown in FIG. 3with the fiber optic adapter removed to show an alignment housing with amulti-fiber alignment device; in accordance with the principles of thepresent disclosure;

FIG. 5 is an enlarged view of a portion of the duplex fiber opticconnector shown in FIG. 4;

FIG. 6 illustrates a schematic view of portions of a ferrule-less fiberoptic connector in accordance with the principles of the presentdisclosure, the fiber optic connector is shown with a retractable nosepiece;

FIG. 7 illustrates a cross-sectional view of a portion of theferrule-less fiber optic connector shown in FIG. 6;

FIG. 8 is a cross-sectional view showing the ferrule-less fiber opticconnector shown in FIG. 1, the fiber optic connector is shown with ashutter in a closed position and a nose piece in an extended position;

FIG. 9 illustrates the ferrule-less fiber optic connector of FIG. 8 withthe shutter in an open position and the nose piece in a retractedposition;

FIG. 10 illustrates an example multi-fiber alignment device inaccordance with the principles of the present disclosure;

FIG. 10A is an isolated view of a portion of the multi-fiber alignmentdevice shown in FIG. 10;

FIG. 11 illustrates another example multi-fiber alignment device inaccordance with the principles of the present disclosure;

FIG. 11A is an isolated view of a portion of the multi-fiber alignmentdevice shown in FIG. 11;

FIGS. 12-13 illustrate another example multi-fiber alignment device inaccordance with the principles of the present disclosure;

FIGS. 14-15 illustrate another example multi-fiber alignment device inaccordance with the principles of the present disclosure;

FIGS. 16-19 illustrate yet another example multi-fiber alignment devicein accordance with the principles of the present disclosure;

FIGS. 20-21 illustrate an example single-fiber alignment device inaccordance with the principles of the present disclosure;

FIGS. 22-23 illustrate an example single-fiber alignment device inaccordance with the principles of the present disclosure;

FIGS. 24-29 illustrate another example single-fiber alignment device inaccordance with the principles of the present disclosure;

FIGS. 30-33 illustrate another example single-fiber alignment device inaccordance with the principles of the present disclosure;

FIGS. 34-37 illustrate another example single-fiber alignment device inaccordance with the principles of the present disclosure;

FIGS. 38-41 illustrate another example single-fiber alignment device inaccordance with the principles of the present disclosure;

FIG. 42 illustrates a first perspective view of an optical transceivermodule adapted to interface with the duplex fiber optic connector ofFIG. 3;

FIG. 43 illustrates a second perspective view of the optical transceivermodule of FIG. 42;

FIG. 44 is a schematic depiction of the optical transceiver module ofFIG. 42;

FIGS. 45-47 illustrate an example alignment system in accordance withthe principles of the present disclosure;

FIGS. 48-49 are exploded views of the alignment system of FIGS. 45-46 toshow an example housing with another example multi-fiber alignmentdevice;

FIG. 50 is an exploded view of the multi-fiber alignment device shown inFIGS. 48-49;

FIGS. 51-52 illustrate another example multi-fiber alignment device inaccordance with the principles of the present disclosure;

FIG. 53 illustrates an end view of the multi-fiber alignment device ofFIGS. 51-52 mounted inside of the housing of FIGS. 48-49;

FIGS. 54-55 illustrate another example multi-fiber alignment device inaccordance with the principles of the present disclosure;

FIG. 56 illustrates an end view of the multi-fiber alignment device ofFIGS. 54-55 mounted inside of the housing of FIGS. 48-49;

FIG. 56A is an enlarged view of a portion of FIG. 56;

FIGS. 57-58 illustrate another example multi-fiber alignment device inaccordance with the principles of the present disclosure;

FIG. 59 illustrates an end view of the multi-fiber alignment device ofFIGS. 57-58 mounted inside of the housing of FIGS. 48-49;

FIG. 60 illustrates another example alignment system in accordance withthe principles of the present disclosure;

FIG. 61 illustrates an end view of the alignment system of FIG. 60;

FIGS. 62-63 are partial exploded views of the alignment system of FIGS.60-61 showing an example housing and another example multi-fiberalignment device in accordance with the principles of the presentdisclosure;

FIG. 64 is an exploded view of the alignment system of FIG. 60;

FIG. 64A is a perspective view of a housing piece shown in FIG. 64;

FIG. 64B is an example mold insert in accordance with the principles ofthe present disclosure;

FIG. 65 is an exploded bottom view of the alignment system of FIG. 60;

FIG. 66 is a side view of the alignment system of FIG. 60;

FIG. 67 is a cross-sectional view taken generally along line 67-67, FIG.66;

FIG. 68 is another end view of the alignment system of FIG. 60;

FIG. 69 is a cross-sectional view taken generally along line 69-69, FIG.68;

FIG. 70 is a cross-sectional view of the multi-fiber alignment deviceshown in FIG. 62;

FIG. 71 is an enlarged view of a portion of FIG. 70; and

FIGS. 72-82 are schematic views illustrating step-by-step movements ofan optical fiber being inserted within the multi-fiber alignment deviceof FIG. 62.

DETAILED DESCRIPTION

Reference will now be made in detail to the exemplary aspects of thepresent disclosure that are illustrated in the accompanying drawings.Wherever possible, the same reference numbers will be used throughoutthe drawings to refer to the same or like structure.

As used herein, a “ferrule” is a relatively hard structure adapted toreceive and support an optical fiber near the end or at the end of theoptical fiber. A ferrule is typically adapted to assist in providingalignment of an optical fiber with a corresponding optical fiber of amated fiber optic connector. In the case of single-fiber ferrules, suchferrules are often cylindrical and often have a construction made ofceramic or of relatively hard plastic. Examples of these types offerrules can include SC ferrules and LC ferrules. Ferrules can alsoinclude multi-fiber ferrules that receive and support a plurality ofoptical fibers. An example multi-fiber ferrule can include an MPOferrule.

As used herein, a bare fiber is a section of optical fiber that does notinclude any coating. Instead, the bare fiber includes a core surroundedby a cladding layer. The optical fiber is “bare” because the claddinglayer is exposed and not covered by a supplemental coating layer such asacrylate.

Optical connectors can include ferrule-less optical connectors. Forexample, an example ferrule-less optical connector 10 known in the artis shown at FIG. 1. The optical connector 10 includes a connector body12 having a front mating end 14 and a rear cable terminating end 16. Anoptical fiber extends forwardly through the connector body 12 and has aferrule-less end portion that is accessible at the front mating end 14of the connector body 12. The optical fiber is anchored adjacent therear cable terminating end 16 against axial movement relative to theconnector body 12. When two optical connectors 10 are coupled together,the end faces of the ferrule-less end portions abut one another, therebycausing the optical fibers to be forced rearwardly into the connectorbodies 12 and to buckle/bend within fiber buckling regions of theconnector bodies 12. A shutter 18 moves between closed and openpositions. The shutter 18 protects the ferrule-less end portion of theoptical fiber from contamination when shut and allows access to theferrule-less end portion when open.

The optical connector 10 also includes a latch 20 that engages a catch22 of a fiber optic adapter 24 (see FIG. 2). The latch 20 includes aresilient cantilever style latch. When the optical connectors 10 areinserted within the coaxially aligned ports of the adapter 24, theshutters 18 of the optical connectors 10 are retracted, thereby exposingthe ferrule-less ends of the optical fibers. Continued insertion causesthe ferrule-less ends to enter an optical fiber alignment device. Otherexamples of ferrule-less optical connectors and corresponding opticaladapters can be found in U.S. patent application Ser. No. 14/377,189,filed Aug. 7, 2014, and titled “Optical Fiber Connection SystemIncluding Optical Fiber Alignment Device,” the disclosure of which isincorporated herein by reference.

FIG. 3 shows a fiber optic connection system 26 in accordance with theprinciples of the present disclosure. The fiber optic connection system26 includes a duplex fiber optic connector 28 and a fiber optic adapter30 (e.g., secure engagement). The duplex fiber optic connector 28 isdepicted as a ferrule-less fiber optic connector. The fiber opticadapter 30 includes adapter ports 32 for receiving the duplex fiberoptic connector 28. In the depicted example of FIG. 3, the duplex fiberoptic connectors 28 a and 28 b are shown loaded within respectiveadapter ports 32 of the fiber optic adapter 30. The duplex fiber opticconnectors 28 a and 28 b are respectively adapted to be optically andmechanically coupled to another one of a duplex fiber optic connector(not shown). It will be appreciated that the duplex fiber opticconnectors 28 a and 28 b can have identical configurations and thereforethe general reference number 28 is applicable to each of the duplexfiber optic connectors 28 a and 28 b.

FIGS. 4-5 are perspective views showing the duplex fiber opticconnectors 28 a and 28 b removed from the fiber optic adapter 30. Thefiber optic adapter 30 is arranged and configured to include amulti-fiber alignment device 34 (e.g., a fiber alignment block, a fiberalignment mechanism, etc.) that provides an alignment interface forrespectively aligning optical fibers of the duplex fiber opticconnectors 28 a, 28 b with optical fibers of another duplex fiber opticconnector (not shown). Although a multi-fiber alignment device is shown,the features and advantages of the present disclosure may also relate toa single fiber alignment device. As shown, the multi-fiber alignmentdevice 34 is housed within an alignment housing 36 that is arranged andconfigured to mount within the fiber optic adapter 30. Examplemulti-fiber alignment devices 34 are illustrated and described in detailwith reference to FIGS. 10-41. It will be appreciated that such examplescan also relate to single fiber alignment devices.

Optical fibers of the duplex fiber optic connectors 28 a, 28 b can bereceived within the multi-fiber alignment device 34 such that the fibersare co-axially aligned with optical fibers of another duplex fiber opticconnector (not shown). The duplex fiber optic connectors 28 a and 28 beach include flexible latches 38 having retention catches 40 thatmechanically retain the duplex fiber optic connectors 28 a, 28 b withintheir corresponding adapter ports 32 of the fiber optic adapter 30. Itwill be appreciated that the multi-fiber alignment device 34 is adaptedto receive optical fibers that are not supported by or secured withincorresponding ferrules. It will also be appreciated that each of theduplex fiber optic connectors 28 a, 28 b and fiber optic adapter 30 arecomprised entirely of non-metallic materials, e.g. plastics, polymers,etc. The absence of any metal within the duplex fiber optic connectors28 a, 28 b and fiber optic adapter 30 creates an interference-freesignal environment.

In certain examples, the multi-fiber alignment devices 34 can be mountedgenerally at a mid-plane of the fiber optic adapter 30. The adapterports 32 can include keyways 42 (see FIG. 8) that receive correspondingkeys 44 of the duplex fiber optic connectors 28. The keys 44 and keyways42 can be configured to interface such that the duplex fiber opticconnectors 28 can only be inserted into the adapter ports 32 in oneorientation. As depicted, each of the duplex fiber optic connectors 28includes two keys 44 a, 44 b (see FIG. 5) respectively positioned onboth sides of the duplex fiber optic connectors 28 a, 28 b. The keys 44a, 44 b can each have a width that extends substantially across anentire width of the duplex fiber optic connectors 28 a, 28 b. In certainexamples, keys 44 a, 44 b have widths that extend across at least amajority of the width of the duplex fiber optic connector 28. In certainexamples, the keys 44 can be provided on only one side of the duplexfiber optic connectors 28 a, 28 b so as to provide a readily apparentvisual and physical cue to an installer regarding the proper orientationof the duplex fiber optic connectors 28 a, 28 b during insertion intothe fiber optic adapter 30.

Still referring to FIG. 4, the duplex fiber optic connectors 28 a, 28 beach include a connector body 46 a, 46 b having a front end 48 and anopposite rear end 50. The connector body 46 a, 46 b defines alongitudinal axis 52 that extends through the connector body 46 in anorientation that extends from the front end 48 to the rear end 50 of theconnector body 46.

Turning to FIG. 6, optical fibers 54 extend through the connector body46 from the rear end 50 to the front end 48. The optical fibers 54 havefiber ends 56 accessible at the front end 24 of the connector body 46.The duplex fiber optic connectors 28 a, 28 b each include a retractablenose piece 58 a, 58 b (see FIG. 5) respectively mounted at the front end48 of the connector body 46 a, 46 b. It will be appreciated that thenose pieces 58 a, 58 b of the duplex fiber optic connectors 28 a and 28b can have identical configurations and therefore the general referencenumber 58 is applicable to each of the nose pieces 58 a, 58 b of theduplex fiber optic connectors 28 a and 28 b.

As shown in FIGS. 7-9 with reference to the optical connector 10 and theduplex fiber optic connector 28, the nose piece 58 defines fiberpassages 60 through which the optical fibers 54 extend. The nose piece58 is movable along the longitudinal axis 52 between an extendedposition (see FIG. 8) where a front end portion 62 of the optical fibers54 is protected within the fiber passages 60 and a retracted position(see FIG. 9) where the front end portion 62 of the optical fibers 54project forwardly beyond the nose piece 58. In certain examples, theoptical connector 10 and duplex fiber optic connectors 28 a and 28 b caneach include a spring 64 for biasing the nose piece 58 toward theextended position. In certain examples, the nose piece 58 retracts backinto the respective connector body 12, 46 as the nose piece 58 movesfrom the extended position toward the retracted position. In certainexamples, relative movement is permitted between the nose piece 58 andthe optical fibers 54 so that the nose piece 58 can slide relative tothe optical fibers 54. As shown in FIG. 5, the nose piece 58 can bearranged and configured to coarsely align with the alignment housing 36upon insertion of the duplex fiber optic connector 28 into the fiberoptic adapter 30. In certain examples, a tip of the nose piece 58 abutsagainst the multi-fiber alignment device 34.

The nose piece 58 can define a cavity 66 (see FIG. 6) that receivesfiber tips of the optical fibers 54 when the nose piece 58 is not in theretracted position. The cavity 66 can be at least partially filled witha non-gaseous fluid (e.g., a refractive index matching gel) forencapsulating the fiber tips 56. In certain examples, the non-gaseousfluid can be filled in the cavity 66 in a volume slightly less than avolume of the cavity. The cavity 66 can be in fluid communication withthe fiber passage 60 such that the fiber tips 56 of the optical fibers54 pass therethrough to be cleaned prior to coupling (e.g., mating). Therefractive index gel can have a refractive index between 1.45 and 1.60,although alternatives are possible.

In certain examples, the non-gaseous fluid functions to clean the endfaces of the optical fibers 54 when the end faces are inserted therein.In certain examples, the non-gaseous fluid generally maintains its shapebut has a viscosity that allows the non-gaseous fluid to flow orotherwise move so as to receive the fiber tips of the optical fibers 54.The optical fibers 54 remain immersed in the non-gaseous fluid while theconnector is in an unmated state.

In certain examples, a fiber anchoring region can be positioned near therear end of the connector body where the optical fiber is fixed inposition relative to the connector body thereby preventing relativeaxial movement between the fiber and the connector body at the anchoringlocation. In certain examples, a fiber buckling region is provided inthe connector body between the anchoring region and the end portion ofthe optical fiber. The buckling region allows the fiber to buckle (i.e.,bend, flex) within the connector body when an optical connection isbeing made.

Referring to FIG. 10, an example multi-fiber alignment device 34 a isdepicted. It will be appreciated that a variety of different types ofmulti-fiber alignment devices can be used to provide coaxial alignmentof the optical fibers of the duplex fiber optic connectors 28 desired tobe optically coupled. Although the design and advantageous features aredescribed herein with reference to the example multi-fiber alignmentdevice 34 a, they can also relate to a single fiber alignment device.

The multi-fiber alignment device 34 a can be molded out of ceramic orlike material, although alternatives are possible. For example, it wouldalso be possible to make the multi-fiber alignment device 34 a out ofplastic, glass, metal, or any other known material. By using a moldablematerial, the multi-fiber alignment device 34 a may be quickly andeasily manufactured as a one piece unit.

The multi-fiber alignment device 34 a is provided to precisely alignindividual fibers of optical connectors secured within ports of anadapter for alignment with fibers in another like connector. Themulti-fiber alignment device 34 a can be referred to as ferrule-lessmulti-fiber alignment device since it provides optical fiber alignmentwithout using or receiving ferrules (e.g., SC ferrules, LC ferrules,etc.). It will be appreciated that the arrangement and configuration ofthe multi-fiber alignment devices 34 described herein would be the samefor both mating sides of the duplex fiber optic connectors 28. As such,only half of the multi-fiber alignment device 34 a would be describedwith respect to the duplex fiber optic connectors 28.

The multi-fiber alignment device 34 can include fixed sized holes 68(e.g., a rigid hole) that each define an alignment passage 70 extendingalong a fiber insertion axis 72 to receive the optical fiber 54. Thefixed sized holes 68 can each have a fixed effective diameter. Herein bythe term, “fixed” and variants thereof, in this context, it is meantthat the diameter of the fixed sized holes does not change when anoptical fiber is inserted therein.

The fixed effective diameter of the fixed sized holes 68 may be largerthan a nominal diameter of the optical fiber 54 that is intended to beinserted therethrough. In one example, a fixed effective diameter of thefixed sized holes 68 is no more than 1.5 microns larger than a maximumouter diameter of the optical fiber 54 to be inserted therein. In oneexample, a fixed effective diameter of the fixed sized holes 68 is nomore than 1.0 microns larger than a maximum outer diameter of theoptical fiber 54 to be inserted therein. In other examples, a fixedeffective diameter of the fixed sized holes 68 is no more than 0.5microns larger than a maximum outer diameter of the optical fiber 54 tobe inserted therein. In certain examples, a fixed effective diameter ofthe fixed sized holes 68 is no more than 2 microns larger than a maximumouter diameter of the optical fiber 54 to be inserted therein. In oneexample, a fixed effective diameter can be in the range of about 125.5microns to about 126.5 microns.

The fixed sized holes 68 can have tolerances in the range of ±0.3microns. In certain examples, the optical fiber 54 has a diameter ofbetween about 124 microns to about 125 microns, although alternativesare possible. The optical fiber 54 can have tolerances in the range of±0.5 microns. It is important to note that tolerances will varydepending upon the material used for the multi-fiber alignment device 34a. While the tolerance ranges are important to the proper operation ofthe present invention, it will be recognized that greater or lesserdiameters may be used, without departing from the spirit or scope of thepresent disclosure.

In certain examples, the multi-fiber alignment devices 34 may notinclude any structure associated with the fixed sized holes 68 thatdeflects upon insertion of the optical fibers. For example, themulti-fiber alignment device 34 can be free of depressing members (e.g.,rods, flexible cantilevers, or other angled transition surfaces) thatcan deflect (e.g., flex, move) upon insertion of optical fibers in thefixed sized holes 68.

In one example, the multi-fiber alignment device 34 h can include analignment body, a first fixed sized hole being defined in the alignmentbody, and a second fixed sized hole being defined in the alignment body.The first fixed sized hole defining a first passage that extends along afiber insertion axis to receive a first optical fiber; the second fixedsized hole defining a second passage that extends along the fiberinsertion axis to receive a second optical fiber. The first and secondpassages can be co-axially aligned. The alignment device does notinclude any structure associated with the first and second fixed sizedholes that deflects upon insertion of the first and second opticalfibers.

As depicted in FIG. 10, the fixed sized holes 68 are generally roundholes. The multi-fiber alignment device 34 a includes fixed sized holes68 defined at first and second ends 80, 82 for mating duplex fiber opticconnectors 28. Each of the first and second sides 80, 82 are independentto allow for two fiber insertions. The fixed sized holes 68 of themulti-fiber alignment device 34 a can have a rigid construction thatallows the fixed sized holes 68 of the multi-fiber alignment device 34 ato be machined to very tight tolerances. The fixed sized holes 68 arearranged and configured to remain the same size and not change overtime. The fixed sized holes 68 allows for a tight tolerance with theoptical fiber 54 which helps to deliver low insertion loss.

In certain examples, the alignment passage 70 of the fixed sized holes68 can have different transverse cross-sectional shapes such asoctagonal shapes, circular shapes, triangular shapes, square shapes, orother shapes. In certain examples, the alignment passage 70 of themulti-fiber alignment device 34 a may include a non-gaseous fluid at theentry thereof to receive and protect the tips of the front end portions62 of the optical fibers 54. In certain examples, a non-gaseous fluidcan at least partially, or completely, fill the alignment passage 70 asto help prevent contamination from entering and help to eliminate thecollection of debris within the alignment passage 70. In certainexamples, a non-gaseous fluid can have a gel-like composition and can beconfigured to deform or flow in order to receive the tips of the frontend portions 62. In certain examples, the non-gaseous fluid can includea gel such as an index matching gel. In certain examples, the fluid canclean the fiber tips as the fiber tips are inserted through the fluid.

In certain examples, a plurality of projections 74 can extend outwardlyfrom an interior surface 76 of the fixed sized holes 68. In one example,the projections 74 may extend longitudinally along an entire length ofthe alignment passage 70. In other examples, the projections 74 mayextend partially along the length of the alignment passage 70. In theexample depicted, the projections 74 are of generally rectangular shape,but may of course be formed with other shapes. In certain examples, thefixed effective diameter can be defined by tips of the projections 74positioned within the fixed sized holes 68, although alternatives arepossible.

The plurality of projections 74 can help to reduce the amount of debris(e.g., dust, dirt) that may collect within the fixed sized holes 68. Forexample, the plurality of projections can define debris collectionregions thereinbetween. Thus, rather than having contamination collectwithin the alignment passages 70, which may prevent insertion of theoptical fiber 54, the debris can collect within gaps formed between theprojections 74. In other examples, the alignment passage 70 may beconfigured with grooves for collecting debris.

The multi-fiber alignment device 34 a can include a cavity region 78that is in fluid communication with the alignment passage 70. The cavityregion 78 can be positioned between the first and second ends 80, 82 ofthe multi-fiber alignment device 34 a. The cavity region 78 can includean open side. The first end 80 defines the fixed sized holes 68 and thesecond end 82 defines similar fixed sized holes (not shown). Thealignment passage 70 of the fixed sized holes 68 positioned at the firstend 80 of the multi-fiber alignment device 34 a can extend along thefiber insertion axis 72 from the first end 80 in a direction toward thecavity region 78. The alignment passage 70 of the fixed sized holes 68at the second end 82 of the multi-fiber alignment device 34 a can extendalong the fiber insertion axis 72 from the second end 82 in a directiontoward the cavity region 78 at an opposite side of the cavity region 78from the alignment passage 70 of the fixed sized hole 68 at the firstend 80 of the multi-fiber alignment device 34 a.

When the duplex fiber optic connectors 28 are respectively mated at thefirst and second ends 80, 82, their respective optical fibers meet inthe center of the cavity region 78. The cavity region 78 positioned toseparate the passages 70 of the respective optical fibers. The cavityregion 78 can have an open side. The cavity region 78 can be at least bepartially filled with a non-gaseous fluid, such as, a refractive indexmatching gel, although alternatives are possible. The optical fiberspass through the refractive index matching gel in the cavity region 78to clean end faces of the optical fibers prior to mating. In certainexamples, the multi-fiber alignment device 34 a includes a lead-inchamfer to facilitate guiding of the optical fiber into the alignmentpassage.

In certain examples, the plurality of projections 74 of the fixed sizedholes 68 defined at the first end 80 of the multi-fiber alignment device34 a can extend longitudinally along the alignment passage 70 from thefirst end 80 of the multi-fiber alignment device 34 a to the cavityregion 78. Similarly, the plurality of projections 74 of the fixed sizedholes 68 defined at the second end 82 of the multi-fiber alignmentdevice 34 a can extend longitudinally along the alignment passage 70from the second end 82 of the multi-fiber alignment device 34 a to thecavity region 78.

In one example, the fixed sized holes 68 of the multi-fiber alignmentdevice 34 can include a first fixed sized hole defining a first passageextending along a fiber insertion axis 72 for receiving a first opticalfiber and a second fixed sized hole defining a second passage forreceiving the second optical fiber. The second passage can be alignedalong the fiber insertion axis 72 and can be co-axial with the firstpassage. The multi-fiber alignment device can include a cavity region 78that forms a gap separating the first and second passages. Ends of thefirst and second optical fibers can meet and be co-axially aligned atthe cavity region.

Referring to FIG. 11, another example multi-fiber alignment device 34 bis to depicted. The multi-fiber alignment device 34 b can be embodiedwith some of the same features and advantages as the multi-fiberalignment device 34 a described above. For the sake of brevity, onlythose portions that differ from the multi-fiber alignment device 34 aillustrated in FIG. 10 discussed above will be described in detail.

Similar to the multi-fiber alignment device 34 a described above, themulti-fiber alignment device 34 b includes fixed sized holes 68 a (e.g.,rigid holes). In the example shown, the fixed sized holes 68 a are alsodefined at both the first and second ends 80, 82. The fixed sized holes68 a are arranged and configured with an opening 84 defined in a topsurface 86 of the multi-fiber alignment device 34 b. The opening 84 isgenerally v-shaped as it extends downwardly from the top surface 86 tothe fixed sized hole 68 a, although alternatives are possible. Incertain examples, the multi-fiber alignment device 34 b includes alead-in chamfer to facilitate guiding of the optical fiber into thealignment passage.

The fixed sized holes 68 a can include grooves 88 that are defined in aninterior surface 76 a of the alignment passage 70 a. Similar to theprojections 74 described above, the grooves 88 can reduce the collectionof contamination within the alignment passage 70 a by providing alocation for which debris can collect.

The multi-fiber alignment device 34 b also includes a cavity region 78 apositioned between the first and second ends 80, 82 of the multi-fiberalignment device 34 b. The cavity region 78 forms a gap separating thefirst and second passages. Ends of the first and second optical fiberscan meet and be co-axially aligned at the cavity region 78 a. The cavityregion 78 a includes the same features and advantages as the cavityregion 78 illustrated in FIG. 10.

Referring to FIGS. 12 and 13, another example multi-fiber alignmentdevice 34 c is depicted. The multi-fiber alignment device 34 c isembodied with some of the same features and advantages as themulti-fiber alignment devices 34 a, 24 b described above. For the sakeof brevity, only those portions that differ from the multi-fiberalignment devices 34 a, 34 b illustrated in FIGS. 10 and 11 discussedabove will be described in detail.

The multi-fiber alignment device 34 c defines slotted fixed sized holes90 at first and second ends 80, 82. The multi-fiber alignment device 34c includes a base member 92, a first flexible jaw flange 94 positionedat the first end 80, and a second flexible jaw flange 96 positioned atthe second end 82. The first flexible jaw flange 94 cooperates with thebase member 92 to define a split-sleeve 98 and the second flexible jawflange 96 cooperates with the base member 92 to another split-sleeve 98that is co-axially aligned with the split-sleeve 98. The first andsecond flexible jaw flanges 94, 96 can be moved between a non-alignmentposition where the split-sleeves 98 are opened to allow for insertion ofoptical fibers, and an alignment position where the split-sleeves 98 areclosed to tighten down on fiber cladding of the optical fibers to lockoptical fibers independently in the split-sleeves.

In certain examples, the optical fibers may come into contact with thefixed sized slotted holes 90 when in the alignment position. In otherexamples, the slotted fixed sized holes 90 have a diameter larger than amaximum outer diameter of the optical fiber extending therethrough whenin the alignment position.

The multi-fiber alignment device 34 c can also include a detachablesecure mechanism (e.g., clamp, pin, clip, or any actuator structure)(not shown). The detachable secure mechanism can be respectively mountedon the first and second flexible jaw flanges 94, 96 to bias the firstand second flexible jaw flanges 94, 96 between the alignment positionand the non-alignment position. For example, the detachable securemechanism can apply a downward force in a direction D₁ (See FIG. 13)onto the first and second flexible jaw flanges 94, 96 such that thefirst and second flexible jaw flanges 94, 96 can be flexed in thedirection D₁ toward the base member 92. The downward force and flexibleaction of the first and second flexible jaw flanges 94, 96 can make theslotted fixed sized holes 90 smaller such that the slotted fixed sizedholes 90 tighten down on fiber cladding of the optical fiber positionedtherein.

The first and second flexible jaw flanges 94, 96 can be actively openedand closed with an actuator structure (not shown) or similar device. Inone example, the first and second flexible jaw flanges 94, 96 of themulti-fiber alignment device 34 c can be configured initially such thatthe slotted fixed sized holes 90 are opened or large. For example, theslotted fixed sized holes 90 may have an inner diameter of about 130microns or greater. An actuator structure can then be used to clamp theslotted fixed sized holes 90 shut to make them smaller and tighteneddown on the optical fibers. In other examples, the first and secondflexible jaw flanges 94, 96 of the multi-fiber alignment device 34 c canbe configured initially such that the slotted fixed sized holes 90 aresmall and nearly shut closed. For example, the slotted fixed sized holes90 may have an inner diameter of about 124 microns or less. An actuatorstructure can also be used to force open the split sleeve to open theslotted fixed sized holes 90 to about 126 microns or more to allow forinsertion of the optical fibers. Once the optical fibers are inserted,the actuator structure disengages to release the split-sleeve 98 toallow the slotted holes 90 to close, compress, or shut tightly aroundthe fiber cladding.

The slotted fixed sized holes 90 can include projections and/or groovesthat are defined in an alignment passage 70 b to reduce the collectionof contamination within the alignment passage 70 b by providing alocation for which debris can collect.

The multi-fiber alignment device 34 c also includes an open region 100that may be filled with a non-gaseous fluid to clean fiber tips andimprove optical mating.

Referring to FIGS. 14 and 15, another example multi-fiber alignmentdevice 34 d is depicted with slotted fixed sized holes 90 a at first andsecond ends 80, 82. The multi-fiber alignment device 34 d is embodiedwith some of the same features and advantages as the multi-fiberalignment device 34 c described above. For the sake of brevity, onlythose portions that differ from the multi-fiber alignment device 34 cillustrated in FIGS. 12 and 13 discussed above will be described indetail.

The multi-fiber alignment device 34 d includes a first side member 102,a first flexible jaw flange 94 a that together act as a split sleeve 98a positioned at the first end 80. The multi-fiber alignment device 34 dincludes a second side member 104 and a second flexible jaw flange 96 athat together act as a split sleeve 98 a positioned at the second end82. The first and second flexible jaw flanges 94 a, 96 a can berespectively moved in directions D₂, D₃ (see FIG. 14) between anon-alignment position where the slotted fixed sized holes 90 a areopened to allow for insertion of optical fibers, and an alignmentposition where the slotted fixed sized holes 90 a are closed to tightendown on fiber cladding of the optical fibers as described above withreference to FIGS. 12-13. The multi-fiber alignment device 34 d caninclude an open region 100 a that may be filled with a non-gaseous fluidto clean fiber tips and improve optical mating.

In one example, the fixed sized holes 68 a of the multi-fiber alignmentdevice 34 a can include a first fixed sized hole defining a firstpassage extending along a fiber insertion axis 72 for receiving a firstoptical fiber and a second fixed sized hole defining a second passagefor receiving the second optical fiber. The second passage can bealigned along the fiber insertion axis 72 and can be co-axial with thefirst passage.

In certain examples, the first and second passages can have open sides.The first and second passages can include hole-defining portions havingcircular curvatures. The hole-defining portions can be moveable betweena first position where the hole-defining portions define a firstdiameter and a second position where the hole-defining portions define asecond diameter. The first diameter can be larger than the seconddiameter. In some examples, a gel-filled gap can be positioned betweenthe first and second passages. The hole-defining portions can beelastically biased toward the first position and elastically biasedtoward the second position.

In certain examples, the hole-defining portions can be moveable betweena first position where the hole-defining portions define a firstdiameter along at least a majority of lengths of the first and secondpassages, and a second position where the hole-defining portions definea second diameter along at least a majority of the lengths of the firstand second passages. The first diameter can be larger than the seconddiameter.

The multi-fiber alignment device 34 d can include a lead-in chamfer 106to facilitate guiding of the optical fiber into the alignment passage 70c. The slotted holes 90 a can include projections or grooves to helpreduce the collection of contamination within the alignment passage 70 cby providing a location for which debris can collect.

Referring to FIGS. 16-19, another example multi-fiber alignment device34 e is depicted. The multi-fiber alignment device 34 e is embodied withsome of the same features and advantages as the multi-fiber alignmentdevice 34 a described above. For the sake of brevity, only thoseportions that differ from the multi-fiber alignment device 34 aillustrated in FIG. 10 discussed above will be described in detail.

The example multi-fiber alignment device 34 e includes an alignmentpassage 70 d that has a combination of a v-groove (e.g., half circle,sphere, etc.) region 108 and a rigid hole alignment region 110. Themulti-fiber alignment device 34 e has a lead-in section 112 (e.g.,opening, hole) which provides access to the v-groove region 108 forreceiving the optical fibers. The lead-in section 112 may include achamfer to facilitate guiding of the optical fiber into the v-grooveregion 108 of the alignment passage 70 d by providing “funnels”, showngenerally at 114 (see FIG. 17) to get the optical fiber started in itsv-groove region 108. The v-groove region 108 can provide coarsealignment (e.g., pre-alignment) by locating and positioning the opticalfiber into the alignment passage 70 d. The v-groove region 108 can becreated with different widths to accommodate different size fibers. Theoptical fibers can be securely held in place by lever members 116 (seeFIG. 17) respectively positioned in the multi-fiber alignment device 34e. The lever members 116 press the optical fiber toward a v-groove or agap or slot defined by the v-groove region 108. Distal ends 118 of thelever members 116 facilitate centering and pre-alignment of the opticalfibers. The distal ends 118 can extend downwardly in a recess 120 at anangle toward the optical fibers positioned in the v-groove region 108.It will be appreciated that the arrangement and configuration of thelever members 116 may vary in other examples such that they do not angledownward into the recess 120. The distal ends 118 of the lever members116 are flexible and configured for urging the optical fibers into theirrespective v-groove regions 108.

Referring to FIG. 18, the rigid hole alignment regions 110 allows forfine adjustment of the optical fiber if the lever members 116 fails tosecure the optical fibers. The rigid hole alignment regions 110 has ashape configured to securely retain the optical fibers therein. Therigid hole alignment regions 110 of the multi-fiber alignment device 34e can be configured as a tight fitting hole to allow for tighttolerances. For example, the rigid hole alignment regions 110 have amuch smaller opening compared with the v-groove region 108 to imposevery tight alignment tolerances. The rigid hole alignment regions 110provide fine alignment generally in a center of the multi-fiberalignment device 34 e just prior to mating.

The rigid hole alignment regions 110 has a short length to help reducethe collection of debris therein. In certain examples, the rigid holealignment regions 110 can include grooves or projections to reduce thecollection of contamination by providing a location for which debris cancollect.

The multi-fiber alignment device 34 e also includes a cavity region 78 bpositioned between the first and second ends 80, 82 of the multi-fiberalignment device 34 e. The cavity region 78 b includes the same featuresand advantages as the cavity region 78 illustrated in FIG. 10. The rigidhole alignment regions 110 can be positioned on opposite sides of thecavity region 78 b such that the optical fiber exiting the rigid holealignment region 110 protrudes into the cavity region 78 b to be matedwith another optical fiber.

Referring to FIGS. 20-21, another example multi-fiber alignment device34 f is provided in accordance with principles of the presentdisclosure. The multi-fiber alignment device 34 f includes an alignmenthousing 122, a center slot 124 formed in the alignment housing 122, andfirst and second bore alignment molds 126, 128 respectively positionedat first and second ends 80, 82. In the depicted example, the first andsecond bore alignment molds 126, 128 are arranged and constructed withfunnels, shown generally at 130, 132 to facilitate guiding of theoptical fibers into its respective rigid hole alignment region 110 a.The rigid hole alignment regions 110 a can provide for tight alignmenttolerances in accordance with principles of the present disclosure.

In one example, the center slot 124 is in fluid communication with therigid hole alignment regions 110 a. This feature provides an advantageof being able to align the optical fibers in the center slot 124 ifduring manufacturing any miss-match of the first and second borealignment molds 126, 128 is created. The alignment housing 122 isdepicted as having a length W₁ of about 4 mm, although alternatives arepossible. The center slot 124 is depicted as having a width W2 of about0.8 mm, although alternatives are possible.

FIGS. 22-23 show another example multi-fiber alignment device 34 g thatis embodied with some of the same features and advantages as themulti-fiber alignment device 34 f described above. For the sake ofbrevity, only those portions that differ from the multi-fiber alignmentdevice 34 f illustrated in FIGS. 20 and 21 discussed above will bedescribed in detail.

In this example, the multi-fiber alignment device 34 g is notconstructed with a round bore. The multi-fiber alignment device 34 g isarranged and constructed with first and second bore alignment molds 134,136 that each include corners 138 (e.g., pockets) similar to a 4-leafclover design. In one example, the optical fiber 54 is aligned andsecured within its respective rigid hole alignment region 110 b betweenthe corners 138 of respective first and second bore alignment molds 134,136. In other examples, the center slot 124 a defined in the alignmenthousing 122 a can be positioned off-center such that the optical fiberscan be aligned in the bore. The example multi-fiber alignment device 34g can allow space for a non-gaseous fluid, such as, gel to disperse andmove out of the way.

FIGS. 24-29 illustrate another example multi-fiber alignment device 34 hthat includes first and second bore alignment molds 126 a, 128 arespectively positioned at first and second ends 80, 82 for aligning twoopposing optical fibers. The first and second bore alignment molds 126a, 128 a each include a rigid hole alignment region 110 c (e.g., fixedsized hole). In the example depicted, the first and second borealignment molds 126 a, 128 a of the multi-fiber alignment device 34 hare constructed in multiple parts. For example, the multi-fiberalignment device 34 h includes a first housing piece 140 (e.g., toppiece, upper body, first part etc.), a second housing piece 142 (e.g.,bottom piece, lower body, second part, etc.), and a sleeve 144. Thefirst and second housing pieces 140, 142 are adapted to be matedtogether. The first and second housing pieces 140, 142 cooperate todefine the rigid hole alignment regions 110 c (e.g., fixed sized holes).The sleeve 144 is arranged and configured to slide over the first andsecond housing pieces 140, 142 to lock the first and second housingpieces 140, 142 in place.

The first housing piece 140 is arranged and configured with the rigidhole alignment region 110 c to align optical fibers 54 while the secondhousing piece 142 includes a flat surface 146 (see FIG. 26), althoughalternatives are possible. For example, the first housing piece 140 mayinclude a flat surface and the second housing piece 142 may include arigid hole alignment region. In certain examples, the first housingpiece 140 defines grooves defining first portions of the rigid holealignment regions 110 c, and the second housing piece 142 includes aflat portion that opposes the grooves and defines second portions of therigid hole alignment regions 110 c. In the depicted example, the firstand second housing pieces 140, 142 are arranged and constructed with“funnels”, shown generally at 130, 132 to facilitate guiding of theoptical fibers 54 into its respective rigid hole alignment region 110 a.Further gel can be positioned within the rigid hole alignment regions110 c.

In one example, a fixed cross-dimension of the rigid hole alignmentregions 110 c is no more than 1.5 microns larger than a maximum outerdiameter of the optical fiber. In other examples, a fixedcross-dimension of the rigid hole alignment regions 110 c is no morethan 1.0 microns larger than a maximum outer diameter of the opticalfiber. In certain examples, a fixed cross-dimension of the rigid holealignment regions 110 c is no more than 0.5 microns larger than amaximum outer diameter of the optical fiber. The fixed cross-dimensionof the rigid hole alignment regions 110 c can be in the range of 125.5to 126.5 microns.

In one example, the rigid hole alignment region 110 c of the firsthousing piece 140 can include a groove 148 (e.g., slot,) (see FIG. 27)that can be a v-groove (e.g., half circle, sphere, etc.) at the bottomto create a two point contact in the groove 148. A third point contactof the groove 148 can be positioned on the second housing piece 142.Thus, the first and second housing pieces 140, 142 create the alignmentgroove for the multi-fiber alignment device 34 h. The features of themulti-fiber alignment device 34 h allow for an open close mold which iseasier to manufacture. Also, with such a design, a venting feature canbe easily implemented into the multi-fiber alignment device 34 h.

FIGS. 30-33 illustrate another example multi-fiber alignment device 34 ithat includes first and second bore alignment molds 126 b, 128 brespectively positioned at first and second ends 80, 82 for aligning twoopposing optical fibers. The first and second bore alignment molds 126b, 128 b each include a rigid hole alignment region 110 d. Themulti-fiber alignment device 34 i is embodied with some of the samefeatures and advantages as the multi-fiber alignment device 34 hdescribed above. For the sake of brevity, only those portions thatdiffer from the multi-fiber alignment device 34 h illustrated in FIGS.24-29 discussed above will be described in detail.

In the example depicted, the multi-fiber alignment device 34 i includestwo parts, a first housing piece 150 (e.g., top piece, upper body, etc.)and a second housing piece 152 (e.g., bottom piece, lower body, etc.)adapted to mate together. The first and second housing pieces 150, 152can be sealed together via lockable sealing clamps 156, althoughalternatives are possible. For example, a snap fit connection interfacemay be used to hold the first and second housing pieces 150, 152together in a closed position. It will be appreciated that some otherfastening feature, or any combination thereof, may be used.

In the example depicted, one of either the first and second housingpieces 150, 152 can contain the rigid hole alignment region 110 d, whilethe other of the first and second housing pieces 150, 152 includes aflat surface 146 a (see FIG. 32). In the example shown, the firsthousing piece includes the flat surface 146 a and the second housingpieces includes the rigid hole alignment region 110 d.

FIGS. 34-37 illustrate another example multi-fiber alignment device 34 jthat includes first and second bore alignment molds 126 c, 128 crespectively positioned at first and second ends 80, 82 for aligning twoopposing optical fibers. The first and second bore alignment molds 126c, 128 c each include a rigid hole alignment region 110 e. Themulti-fiber alignment device 34 j is embodied with some of the samefeatures and advantages as the multi-fiber alignment devices 34 h, 34 idescribed above. For the sake of brevity, only those portions thatdiffer from the multi-fiber alignment devices 34 h, 34 i illustrated inFIGS. 24-33 discussed above will be described in detail.

In the example depicted, the multi-fiber alignment device 34 j includestwo identical housing pieces 158 that include a top piece (e.g., upperbody, etc.) and a bottom piece (e.g., lower body, etc.) adapted to matetogether to create a precision bore with the rigid hole alignment region110 e. In the example depicted, the housing pieces 158 form the rigidhole alignment region 110 e which has a groove 148 b with a round shape,although alternatives are possible. For example, the groove can includea v-shape (e.g., half circle, sphere, etc.). In certain examples, thehousing pieces 158 can be different parts where one of the housingpieces 158 contains a rigid hole alignment region and the other one ofthe housing pieces includes a flat surface. The housing pieces 158 arearranged and constructed with “funnels”, shown generally at 130, 132 tofacilitate guiding of the optical fibers 54 into its respective rigidhole alignment region 110 e.

The housing pieces 158 can be sealed together via lockable sealingclamps, although alternatives are possible. For example, a snap fitconnection interface may be used to hold the housing pieces 158 togetherin a closed position. In the example depicted, pegs 160 are formed onand extend from an inner face 162 of the housing pieces 158 on oppositesides thereof. A hole 164 is defined in the inner face 162 of thehousing pieces 158 to receive the pegs 160 to secure the housing piecestogether 158. It will be appreciated that some other fastening feature,or any combination thereof, may be used.

FIGS. 38-41 illustrate another example multi-fiber alignment device 34 kthat includes first and second bore alignment molds 126 d, 128 drespectively positioned at first and second ends 80, 82 for aligning twoopposing optical fibers. The first and second bore alignment molds 126d, 128 d each include a rigid hole alignment region 110 f. Themulti-fiber alignment device 34 k is embodied with some of the samefeatures and advantages as the multi-fiber alignment devices 34 h, 34 i,34 j described above. For the sake of brevity, only those portions thatdiffer from the multi-fiber alignment devices 34 h, 34 i, 34 jillustrated in FIGS. 24-37 discussed above will be described in detail.

In the example depicted, the multi-fiber alignment device 34 k includestwo parts, an insert piece 166 and an insert housing 168. The inserthousing 168 defines an opening 170 for receiving the insert piece 166therein. The insert housing 168 is adapted to slide over the insertpiece 166. In other examples, the insert housing 168 can be arranged andconfigured with a slot, opening, or undercut in one of its sides.

In the example depicted, the insert piece 166 is arranged and configuredwith the rigid hole alignment region 110 f to align optical fibers 54while the insert housing 168 includes a flat surface 146 c (see FIG.39), although alternatives are possible. For example, the insert piece166 may include a flat surface and the insert housing 168 may include arigid hole alignment region. In the depicted example, the insert piece166 and the insert housing 168 are arranged and constructed with“funnels”, shown generally at 130, 132 to facilitate guiding of theoptical fibers 54 into its respective rigid hole alignment region 110 f.

In one example, the rigid hole alignment region 110 f of the insertpiece 166 can include a groove 148 c (see FIG. 41) that has a v-grooveshape (e.g., half circle, sphere, etc.) at the bottom to create a twopoint contact in the groove 148 c. A third point contact of the groove148 c can be positioned on the insert housing 168.

Another aspect of the present disclosure relates to an opticaltransceiver module 200 depicted in FIGS. 42-44. The optical transceivermodule 200 is adapted to interface with one of the duplex fiber opticconnectors 28. The optical transceiver module 200 includes a housing 202having a first end 204 and a second end 206. An optical interface isprovided at the first end 204 and an electrical interface is provided atthe second end 206. The optical transceiver module 200 can also includecontacts for receiving power and can be configured for transmittingelectrical power through the electrical interface at the second end 206and for directing power to active components (optical to electricalconverters and electrical to optical converters) within the housing 202.In one example, the optical transceiver module 200 can have an industrystandard form factor such as an SFP (Small Form-factor Pluggable) formfactor.

The optical interface at the first end 204 of the housing 202 caninclude a port 208 for receiving one of the duplex fiber opticconnectors 28. The port 208 can have the same configuration as thepreviously described adapter port 32. The electrical interface at thesecond end 206 of the housing 202 can include electrical contacts 210.The electrical contacts 210 are depicted as electrically conductive pads(e.g., card-edge contacts) supported on a printed circuit board, butcould also be conductive springs or other electrically conductiveelements. The fiber optic adapter 30 can also include any of thepreviously described multi-fiber alignment devices 34 a-k for aligningnon-ferrulized optical fibers to provide optical coupling (e.g.,detachable/disengageable optical connections) between non-ferrulizedoptical fibers. As shown at FIG. 44, the multi-fiber alignment devices34 a-k can include first and second fiber alignment passages 212, 214for individually receiving the optical fibers 54 of the duplex fiberoptic connectors 28 when the duplex fiber optic connectors 28 isinserted in the port 208.

The optical transceiver module 200 can includes a transmit component 216(e.g., a light emitting component) and a receive component 218 (e.g., alight receiving component). The transmit component 216 and the receivecomponent 218 are electrically connected to separate electrical contacts210 at the electrical interface of the optical transceiver module (e.g.,via electrical paths such as wires or tracings) and are opticallycoupled to the optical interface (e.g., via optical fibers). Thetransmit component can include structure for converting electricalsignals to optical signals (an electrical to optical converter) and caninclude a light emitter. An example structure can include a laser diodesuch as a Vertical Cavity Surface Emitter Laser (VCSEL) or an edgeemitting laser. The receive component can include structure forconverting optical signals into electrical signals (e.g., an optical toelectrical converter). An example structure can include a photodiode.The optical transceiver module 200 also includes first and secondoptical fibers 220, 222 having first ends received respectively withinthe fiber alignment passages 212, 214 of the multi-fiber alignmentdevice 34. When the duplex fiber optic connector 28 is inserted in theport 208, the multi-fiber alignment device 34 causes (e.g., throughmechanical co-axial alignment) the optical fibers 220, 222 to beoptically coupled to the optical fibers 54 of duplex fiber opticconnector 28. A second end of the first optical fiber 220 can beoptically coupled to the receive component 218 by a direct opticalconnection such as an optical surface mount connection. A second end ofthe second optical fiber 222 can be optically coupled to the transmitcomponent 216 by a direct optical connection such as an optical surfacemount connection. Example optical transceiver modules are disclosed inU.S. Provisional Patent Application Ser. No. 62/419,266 which is herebyincorporated by reference in its entirety.

Certain examples of the present disclosure relate to alignment devicesthat have a plurality of grooves for receiving optical fibers and astructure arranged and configured to hold the optical fibers in arespective one of the plurality of grooves.

As used herein, the term, “groove,” is defined generally as an elongatestructure that can receive and support an optical fiber. In one example,the elongate structure can have two surfaces that are angled such thatwhen an optical fiber lies within the groove, the optical fiber makesline contact with the two surfaces. The elongate structure can bedefined by one component (e.g., a groove in a plate) or multiplecomponents (e.g., a groove defined by two parallel rods).

Generally a groove will have an open side and a closed side in which anoptical fiber sits. In one example, the groove may include a v-groovethat has angled surfaces. In such an example, the v-groove will have astructure that preferably provides two lines of contact with an opticalfiber inserted therein. In this way, the line/point contact with thev-groove assists in providing accurate alignment of the optical fibers.It will be appreciated that the V-shape is not essential, although it isessential that there be a surface or surfaces against which the fibercontacts and is located. For example, a U-shape, or a trough shape, orother similar shape could also be used, or a curved surface with aradius matched to the radius of the optical fiber could be used. Agroove may be formed by the sides of parallel rods.

Certain examples of the present disclosure can include a structure thatcan be used to press optical fibers or hold the optical fibers ingrooves. In one example, the structure may be a flat plate used to pressthe optical fibers in the grooves. The flat plate may provide a rigidbore style alignment, although alternatives are possible. A spring stylestructure may also be used to bias the optical fibers into the grooves.In a preferred example, the spring style structure can be a plate thathas a plurality of elastic members. The plurality of elastic members caninclude cantilever springs, springs integral with plates or other body,metal springs, plastic springs, coil springs, springs biasing additionalcontact structures such as balls, etc., although alternatives arepossible.

Four example fiber alignment devices are illustrated and described indetail with reference to FIGS. 48-59. It will be appreciated that suchexamples can also relate to single fiber alignment devices, but aspectsare particularly applicable to multi-fiber alignment devices foraligning multiple sets of optical fibers. Each of the alignment devicescan include an outer housing. The housing can have a plurality ofopenings and guide surfaces for guiding optical fibers. The housing canbe arranged and configured to hold the alignment device and generallymount the alignment device inside an adapter for receiving ferrule-lessfiber optic connectors. For example, the housing can include flangesthat are adapted to interface with (e.g., be captured in) the adapterfor securing the alignment device therein. It will be appreciated thatthe housing can hold alignment devices of different styles, as will bedescribed below.

Turning to FIGS. 45-47, an example alignment system 400 is depicted inaccordance with the principles of the present disclosure. The alignmentsystem 400 includes a housing and an alignment device. The housing canbe configured to hold the alignment device and to guide optical fibersinto the alignment device. As such, the actual alignment of the opticalfibers occurs inside of the housing. Example adapters for receiving thealignment system 400 are disclosed by U.S. Application Ser. No.62/454,439, herein incorporated by reference in its entirety.

As depicted, the alignment system 400 can include housing 300. Thehousing 300 can have structure that can be used to secure the housing300 inside of a fiber optic adapter. Typically, the housing 300 includesopposing flanges 302 a, 302 b that may be used to mount the housing 300inside of the fiber optic adapter. Multiple fiber insertion openings 304can be provided through the housing 300. While three fiber insertionopenings 304 are provided, it will be appreciated that more or fewerthan three may be utilized without departing from the presentdisclosure. For example, one, two, three, four or more fiber openingscan be provided at each end of the housing 300. In the depicted example,the two outside fiber insertion openings 304 can be used forcompatibility with duplex ferrule-less connectors or the middle fiberinsertion opening 304 can be used for compatibility with ferrule-lessfiber optic connectors having single fibers. The housing 300 may beprovided with a lead-in region 306 to help facilitate guiding of opticalfibers into grooves of an alignment device housed therein.

Referring to FIGS. 48-49, the housing 300 is shown having two separateparts, a first housing part 308 and a second housing part 310. The firstand second housing parts 308, 310 of the housing 300 can have a maleprojection 312 that fits within a corresponding female receptacle 314for connecting the first and second housing parts 308, 310. The firstand second housing parts 308, 310 each include a cavity region 316 forreceiving portions of an example multi-fiber alignment device 318 tohold the multi-fiber alignment device 318 therein.

The example multi-fiber alignment device 318 includes a first housingpiece 320 (e.g., top piece, upper body, first part, etc.) and a secondhousing piece 322 (e.g., bottom piece, lower body, second part, etc.).The first and second housing pieces 320, 322 are adapted to be matedtogether. In one example, the second housing piece 322 forms multipleelongate pockets 324. The multi-fiber alignment device 318 includes agroove-type alignment structure 325. In one example, the groove-typealignment structure 325 (see FIG. 48) can include parallel rods 326,which can be supported by the multiple elongate pockets 324 of thesecond housing piece 322. In certain examples, the parallel rods 326 canbe cylindrical. In certain examples, the parallel rods 326 can haverounded ends. In certain examples, rounded ends can be dome orsemi-spherically shaped.

The multiple elongate pockets 324 can extend from a front end 328 to arear end 330, essentially extending from one end to an opposite end ofthe second housing piece 322, although alternatives are possible. Theparallel rods 326 fit within the elongate pockets 324 and cooperate todefine fiber alignment grooves 332 (see FIG. 47). As such, the fiberalignment grooves 332 can extend continuously from the front end 328 tothe rear end 330 of the second housing piece 322, although alternativesare possible. In certain examples, the rounded ends of the parallel rods326 can be configured to guide or direct optical fibers into the fiberalignment groove 332.

In other examples, the fiber alignment grooves 332 may not extend allthe way from the front end 328 to the rear end 330 of the second housingpiece 322. For example, the second housing piece 322 may have a flat,recessed region positioned between the front and rear ends 328, 330 ofthe second housing piece 322. The flat, recessed region may be afiber-to-fiber interface where ends of first and second optical fibersmeet.

The multi-fiber alignment device 318 can include an intermediate plate334 that cooperates with the groove type alignment structure 325 forpositioning optical fibers in the fiber alignment grooves 332. Theintermediate plate 334 includes structure (e.g., a main body of theintermediate plate) that forces, compresses or otherwise retains/holdsthe rods 326 in the elongate pockets 324 such that the intermediateplate 334 assists in positioning and retaining the rods 326 within theopen sided elongate pockets 324. In one example, the intermediate plate334 also can include a plurality of elastic members 336 (e.g.,cantilever springs, spring biased members, integral springs, metalsprings, plastic springs, etc.) positioned thereon for holding opticalfibers in a respective one of the multiple fiber alignment grooves 332formed by the rods 326. As such, when the first and second housingpieces 320, 322 are mated together, the plurality of elastic members 336of the intermediate plate 334 can assist in retaining optical fibers inalignment along the fiber alignment grooves 332.

Turning again to FIG. 45, the first and second housing parts, 308, 310of the housing 300 meet at a central interface plane 338. In certainexamples, the first and second housing parts 308, 310 can behalf-pieces. The first and second housing parts 308, 310 respectivelydefine opposite first and second ends 340 a, 340 b of the housing 300.The opposite first and second ends 340 a, 340 b define the co-axiallyaligned openings 304 that are aligned along a fiber insertion axis 342that is oriented generally perpendicular relative to the centralinterface plane 338. In certain examples, the fiber insertion axis 342may not be oriented generally at an angle such that an optical fiber canbe pointed downwardly into a fiber alignment groove. Opposing axial endfaces 344 a, 344 b of the flanges 302 a, 302 b mate at the centralinterface plane 338. The flanges 302 a, 302 b cooperate to define acentral flange 302 of the housing 300. The axial end faces 344 a, 344 bof the flanges 302 a, 302 b can include the male projections 312 andfemale receptacles 314.

The first and second housing parts 308, 310 also include barrel-portions346 a, 346 b that project axially outwardly from the flanges 302 a, 302b along the fiber insertion axis 342. The barrel-portions 346 a, 346 binclude axial end faces 348 a, 348 b. The fiber insertion openings 304are defined through the axial end faces 348 a, 348 b. The axial endfaces 348 a, 348 b also include the lead-in region 306 (e.g., transitionportion) that surround the fiber insertion openings 304. The lead-inregion 306 can be configured for guiding or directing optical fibersinto the fiber insertion openings 304. In certain examples, the lead-inregion 306 can be tapered or angled relative to the fiber insertion axis342. In certain examples, the lead-in region 306 can be funnel-shaped.

When the housing 300 is assembled, each fiber alignment groove 332preferably generally aligns with a corresponding fiber insertion axis342 in a coaxial orientation. In certain examples, the fiber alignmentgroove 332 may not be aligned with the fiber insertion axis 342 when thefiber insertion axis 342 is generally oriented at an angle.Additionally, the plurality of elastic members 336 of the intermediateplate 334 have lengths that extend along (e.g., parallel to and above)the fiber alignment groove 332 as well as the fiber insertion axis 342.The plurality of elastic members 336 can be positioned close enough tothe fiber alignment groove 332 to apply sufficient pressure to theoptical fibers received within the fiber alignment groove 332 such thatthe optical fibers are held and retained within the fiber alignmentgroove 332 in coaxial alignment with one another.

Referring to FIG. 50, the first housing piece 320 can be arranged andconfigured to hold the plurality of elastic members 336 of theintermediate plate 334 in position over the fiber alignment groove 332.The plurality of elastic members 336 can help to press optical fibersinto the fiber alignment grooves 332. The intermediate plate 334 caninclude a plastic or polymeric structure (e.g., a molded plastic part)which can include a main body 350. In other examples, the intermediateplate 334 could be metal or include metal or metal/plastic composite.

In one example, the plurality of elastic members 336 is unitarily formedas one piece with the main body 350 of the intermediate plate 334. Forexample, the plurality of elastic members 336 can include base ends 352that are monolithically connected with the main body 350. The pluralityof elastic members 336 can extend from opposite ends of the main body350 such that free ends 354 of the plurality of elastic members 336 areopposing one another. The plurality elastic members 336 can be separatedby recesses 356 defined through the main body 350 of the intermediateplate 334.

In certain examples, opposing free ends 354 of the plurality of elasticmembers 336 can be separated by an intermediate gap 358 centrallylocated between opposite ends of the main body 350 of the intermediateplate 334. The free ends 354 of the plurality of elastic members 336 canbe disposed adjacent the intermediate gap 358.

Turning again to FIG. 49, the free ends 354 (see FIG. 50) can eachinclude a tab portion 360 (e.g., a projection)(see FIG. 49) thatprojects from the main body 350 of the intermediate plate 334 so as toproject closer to the fiber alignment groove 332 to help retain opticalfibers within the fiber alignment grooves 332. In certain examples, thetab portions 360 are the only portions of the plurality of elasticmembers 336 that contact the optical fiber when the optical fiber iswithin the fiber alignment groove 332.

The free ends 354 of the plurality of elastic members 336 can alsoinclude extensions 362 (see FIG. 50) that extend upwardly from oppositesides of the tab portions 360 in a direction toward the first housingpiece 320. The extensions 362 can be elevated or otherwise offset fromthe tab portions 360 so that the extensions 362 are not adapted tocontact the optical fibers within the fiber alignment grooves 332.Instead, the extensions 362 can be received in recesses 364 (see FIG.49) defined in the first housing piece 320 when the first and secondhousing pieces 320, 322 are mated together. The second housing piece 322can cause the plurality of elastic members 336 to flex relative to themain body 350 of the intermediate plate 334 to a position where the tabportions 360 are spaced a predetermined and precisely controlled amountfrom the fiber alignment groove 332 when the rods are pressed in thepocket of the main body 350.

FIGS. 51-52 depict another multi-fiber alignment device 366 inaccordance with the principles of the present disclosure. Themulti-fiber alignment device 366 is configured to mount in a housingsuch as the housing 300 to form another alignment system 400A in accordwith the principles of the present disclosure. The multi-fiber alignmentdevice 366 includes a first housing piece 368 (e.g., top piece, upperbody, first part, etc.) and a second housing piece 370 (e.g., bottompiece, lower body, second part, etc.) The first and second housingpieces 368, 370 are adapted to be mated together. The second housingpiece 370 of the multi-fiber alignment device 366 is embodied with someof the same features and advantages as the second housing piece 322 ofthe multi-fiber alignment device 318 described above. For the sake ofbrevity, only those portions that differ from the multi-fiber alignmentdevice 318 illustrated in FIGS. 48-50 discussed above will be describedin detail.

The multi-fiber alignment device 366 includes the groove-type alignmentstructure 325. In one example, the groove-type alignment structure 325can include parallel rods 326, which can be supported by the multipleelongate pockets 324 of the second housing piece 370. In certainexamples, the parallel rods 326 can be cylindrical. In certain examples,the parallel rods 326 can have rounded ends. In certain examples,rounded ends can be dome or semi-spherically shaped. The multipleelongate pockets 324 can extend from a front end 328 to a rear end 330,essentially extending from one edge to an opposite edge of the secondhousing piece 370, although alternatives are possible. The parallel rods326 fit within the elongate pockets 324 and cooperate to define fiberalignment grooves 372 (see FIG. 53). The rounded ends of the parallelrods 326 can be configured to guide or direct optical fibers into thefiber alignment grooves 372. In other examples, the groove-typealignment structure 325 can also be integral with the second housingpiece 370.

The multi-fiber alignment device 366 does not include an intermediateplate with a plurality of elastic members or any other structures thatdeflect or elastically deform when an optical fiber is inserted in themulti-fiber alignment device 366. The first housing piece 368 mayinclude a flat surface 374 (e.g., holding surface) such that whenoptical fibers are respectively positioned in the fiber alignmentgrooves 372, the flat surface 374 creates a block over the opticalfibers, although alternatives are possible. The flat surface 374 ispreferably a fixed, relatively rigid, fiber-holding surface that is notintended to flex when a fiber is inserted in a corresponding one of thefiber alignment grooves 372. The surface is flat, but in some examplesmay be curved. The flat surface 374 of the first housing piece 368cooperates with the fiber alignment grooves 372 to form rigid bore stylealignment openings when the first and second housing pieces 368, 370 aremated together. The multi-fiber alignment device 366 can be heldtogether in the housing in the same manner described herein with respectto the earlier described example.

FIGS. 54-55 depict another multi-fiber alignment device 376 inaccordance with the principles of the present disclosure. Themulti-fiber alignment device 376 is configured to mount in a housingsuch as the housing 300 to form another alignment system 400B (see FIG.56) in accord with the principles of the present disclosure. Themulti-fiber alignment device 376 includes a first housing piece 378(e.g., top piece, upper body, first part, etc.) and a second housingpiece 380 (e.g., bottom piece, lower body, second part, etc.). The firstand second housing pieces 378, 380 are adapted to be mated together. Thefirst housing piece 378 of the multi-fiber alignment device 376 isembodied with some of the same features and advantages as the firsthousing piece 368 of the multi-fiber alignment device 366 describedabove. For the sake of brevity, only those portions that differ from themulti-fiber alignment device 366 illustrated in FIGS. 51-52 discussedabove will be described in detail.

The multi-fiber alignment device 376 can include a groove-type alignmentstructure that is integral with the second housing piece 380. Forexample, the second housing piece 380 of the multi-fiber alignmentdevice 376 has multiple fiber alignment grooves 382 that are formed inthe second housing piece 380 as v-grooves or other groove shapes, suchas, but not limited to, semi-circular shapes or trough shapes. The fiberalignment grooves 382 can be patterned or made with great precision bymolding techniques, etching techniques, or laser techniques, althoughalternatives are possible.

The second housing piece 380 can be arranged and configured with“funnels”, shown generally at 384 to facilitate guiding optical fibersinto the fiber alignment grooves 382. In certain examples, flatintermediate portions 386 (e.g., recesses) can be formed in a topsurface 388 of the second housing piece 380. The flat intermediateportions 386 can be centrally positioned between the front and rear ends328, 330 of the second housing piece 380.

The fiber alignment grooves 382 can extend through the flat intermediateportions 386. The flat intermediate portions 386 can be recessedrelative to the top surface 388 of the second housing piece 380. Thefiber alignment grooves 382 can have reduced depths as the fiberalignment grooves 382 extend through the flat intermediate portions 386.The flat intermediate portions 386 correspond to recessed regionsrelative to the top surface 388 and provide open space for allowingexcess gel to be collected. In other examples, the flat intermediateportions 386 may have shapes other than flat and can be referred to asrecessed regions or open regions.

Referring to FIG. 56A, the fiber alignment grooves 382 can each providetwo lines of contact with an optical fiber 331 inserted therein. Whenviewed in cross-section or end view, the fiber alignment grooves 382 caneach create a two-point contact 327 with the optical fiber 331 insertedtherein. In certain examples, the flat surface 374 of the first housingpiece 378 can create a third point contact 329 with the optical fiber331 when inserted in the fiber alignment grooves 382. The flat surface374 of the first housing piece 378 blocks the optical fiber 331 in thefiber alignment grooves 382 and can make line contact with the opticalfiber 331 within the fiber alignment groove 382, although alternativesare possible. The flat surface 374 of the first housing piece 378cooperates with the fiber alignment grooves 382 to form rigid bore stylealignment openings when the first and second housing pieces 378, 380 aremated together. The multi-fiber alignment device 376 can be heldtogether in the housing 300 in the same manner described herein withrespect to the earlier described example.

FIGS. 57-58 depict another multi-fiber alignment device 390 inaccordance with the principles of the present disclosure. Themulti-fiber alignment device 390 is configured to mount in a housingsuch as the housing 300 to form another alignment system 400C (see FIG.59) in accord with the principles of the present disclosure. Themulti-fiber alignment device 390 includes a first housing piece 392(e.g., top piece, upper body, first part, etc.) and a second housingpiece 394 (e.g., bottom piece, lower body, second part, etc.). The firstand second housing pieces 392, 394 are adapted to be mated together. Thesecond housing piece 394 of the multi-fiber alignment device 390 isembodied with some of the same features and advantages as the secondhousing piece 380 of the multi-fiber alignment device 376 describedabove. The first housing piece 392 of the multi-fiber alignment device390 is embodied with some of the same features and advantages as thefirst housing piece 320 of the multi-fiber alignment device 318described above. The multi-fiber alignment device 390 can be heldtogether in the housing 300 (see FIG. 59) in the same manner describedherein with respect to the earlier described example. For the sake ofbrevity, only those portions that differ from the multi-fiber alignmentdevices 376, 318 illustrated in FIGS. 48-50 and 54-55 discussed abovewill be described in detail.

The multi-fiber alignment device 390 includes the intermediate plate 334as described above with reference to FIGS. 48-50. The first housingpiece 392 holds the plurality of elastic members 336 of the intermediateplate 334 in place when mated with the second housing piece 394. The tabportions 360 project from the main body 350 of the intermediate plate334 so as to project closer to the v-groove shaped fiber alignmentgroove 382 to help retain optical fibers within the fiber alignmentgrooves 382.

The extensions 362 can be received in recesses 364 defined in the firsthousing piece 392 when the first and second housing pieces 392, 394 aremated together. The first housing piece 392 can cause the plurality ofelastic members 336 to flex relative to the main body 350 of theintermediate plate 334 to a position where the tab portions 360 arespaced a predetermined and precisely controlled amount from the fiberalignment groove 382. In some examples, the plurality of elastic members336 can flex up when optical fibers are inserted in the fiber alignmentgrooves 382. In other examples, the plurality of elastic members 336 canbe held at fixed flexed positions by the second housing piece 394.

In some examples, the flat intermediate portions 386 provide clearancefor the tab portions 360 to project to a lower depth relative to thefiber alignment grooves 382 (e.g., closer to the bottom of the fiberalignment grooves). In some examples, the plurality of elastic members336 can flex up relative to the fiber alignment groove 382 toaccommodate fibers inserted into the fiber alignment grooves 382. Insome examples, the plurality of elastic members 336 flex up until theyengage a positive stop structure of the housing 300 and therefore canfunction similar to a rigid bore style alignment. In other examples, theplurality of elastic members 336 can flex up away from the fiberalignment grooves 382 and not engage a positive stop of the housing 300such that the inherent elasticity of the plurality of elastic members336 provide the pressing force for holding the optical fibers in thefiber alignment grooves 386.

FIGS. 60-63 depict another alignment system 500 in accordance with theprinciples of the present disclosure. The alignment system 500 includesa housing 600 and a fiber alignment device 700. The housing 600 includesfirst and second housing parts, 602 a, 602 b that meet at a centralinterface plane 604. In certain examples, the first and second housingparts 602 a, 602 b can be half-pieces. The first and second housingparts 308, 310 respectively define opposite first and second ends 606 a,606 b of the housing 600. The opposite first and second ends 606 a, 606b define co-axially aligned openings 608 that are aligned along a fiberinsertion axis 610 that is oriented generally perpendicular relative tothe central interface plane 604. Opposing axial end faces 612 a, 612 bof the flanges 602 a, 602 b mate at the central interface plane 604. Theflanges 602 a, 602 b cooperate to define a central flange 602 of thehousing 600. The axial end faces 612 a, 612 b of the flanges 602 a, 602b can include male projections 614 that fit within female receptacles616 for mating the first and second housing parts 602 a, 602 b together.

The first and second housing parts 602 a, 602 b also includebarrel-portions 618 a, 618 b that project axially outwardly from theflanges 602 a, 602 b along the fiber insertion axis 610. Thebarrel-portions 618 a, 618 b include axial end faces 620 a, 620 b. Thefiber insertion openings 608 are defined through the axial end faces 620a, 620 b.

It will be appreciated that the housing 600 defines an internal chamber622 or cavity for receiving a fiber alignment device 700. Additionally,the housing 600 includes internal structures 624 adapted to engage thefiber alignment device 700 to effectively position or center the fiberalignment device 700 within the housing 600 (see FIGS. 66-67).Preferably, the fiber alignment device 700 is located within the housing600 such that an alignment groove structure 702 (e.g., fiber alignmentgroove) (see FIG. 64) of the fiber alignment device 700 drops beneaththe fiber insertion axis 610 and is not coaxially aligned with the fiberinsertion axis 610. The internal structures 624 of the housing 600 canengage opposite sides of the fiber alignment device 700 to secure andcenter the fiber alignment device 700.

The alignment groove structure 702 of the fiber alignment device 700extends from a front end 704 to a rear end 706 of the fiber alignmentdevice 700, essentially extending from one end to an opposite end of thefiber alignment device 700, although alternatives are possible. Thefront and rear ends 704, 706 include transition portions 708 thatsurround a fiber insertion opening 710 that defines a fiber path 707 forreceiving the optical fiber. The fiber path 707 can be defined betweenthe first hand second housing pieces 712, 714. The transition portions708 can be configured for guiding or directing optical fibers into thefiber insertion opening 710. In certain examples, the transitionportions 708 can be tapered or angled relative to the fiber insertionaxis 610. In certain examples, the transition portions 708 can befunnel-shaped.

Referring to FIG. 64, the fiber alignment device 700 includes a firsthousing piece 712 (e.g., top piece, upper body, first part, etc.) and asecond housing piece 714 (e.g., bottom piece, lower body, second part,etc.). The first and second housing pieces 712, 714 are adapted to bemated together. The fiber alignment device 700 is configured to mount inthe housing 600 to form the alignment system 500 in accord with theprinciples of the present disclosure.

Turning to FIG. 64A, the second housing piece 714 defines the alignmentgroove structure 702 (e.g., groove-type fiber alignment structure). Thealignment groove structure 702 may include a v-groove that has angledsurfaces and a constant cross-section along its length. In such anexample, the v-groove will have a structure that preferably provides twolines of contact with an optical fiber inserted therein. In this way,the line/point contact with the v-groove assists in providing accuratealignment of the optical fibers. It will be appreciated that the V-shapeis not essential, although it is essential that there be a surface orsurfaces against which the fiber contacts and is located. For example, aU-shape, or a trough shape, or other similar shape could also be used,or a radius matched to the radius of the optical fiber could be used. Inother examples, rods could also be used. In other examples, a groovewith straight walls (e.g., v-groove) could be used. In still otherexamples, a groove with convex walls could also be used.

The second housing piece 714 includes top surfaces 728 on opposing sidesof the alignment groove structure 702. The alignment groove structure702 and adjacent top surfaces 728 can be created using a mold such as aninsert mold 735 as shown in FIG. 64B. The surfaces of the insert mold735 can be shaped to correspond with the desired shape of the secondhousing piece 714. For example, the insert mold 735 can include aprojection structure 737, flat molding surfaces 739 a, 739 b on oppositesides of the projection structure 737, and structural steps 741 a, 741 brespectively located at opposite ends 743 a, 743 b of the insert mold735. In certain examples, the projection structure 737 can be arrangedand configured to create an open top side 736 (see FIG. 64A) of thealignment groove structure 702. In certain examples, the flat moldingsurfaces 739 a, 739 b can be arranged and configured to create the topsurfaces of the alignment groove structure 702, respectively. In certainexamples, the structural steps 741 a, 741 b can be arranged andconfigured to create the stabilization structures 734 a, 734 b,respectively. This allows the depth of the alignment groove structure702 compared to the top surfaces 728 to be accurately controlled. Thealignment groove structure 702 can be easier to manufacture becausethere are no transitions, tapers, lead-ins or other features at the endof the alignment groove structure 702. As such, the alignment groovestructure 702 can easily be surface ground or lapped to ensure a flatand smooth mold surface.

Referring to FIG. 65, the first housing piece 712 includes first andsecond projections 716 a 716 b respectively positioned at the front andrear ends 704, 706 of the fiber alignment device 700. The first housingpiece 712 also includes a cavity 738 between the first and secondprojections 716 a, 716 b for allowing excess gel to be collectedtherein. The first and second projections 716 a, 716 b can be arrangedand configured to respectively guide first and second optical fibers720, 722 into the alignment groove structure 702 of the fiber alignmentdevice 700.

Referring to FIG. 68, an end view of the alignment system 500 isdepicted.

FIG. 69 is a cross-sectional view of the alignment system 500 takenalong line 69-69 of FIG. 68. The alignment system 500 shows the firstand second optical fibers 720, 722 inserted within the fiber alignmentdevice 700 to be optically coupled at an intended coupling location 726(e.g., fiber to fiber interface location). The intended couplinglocation 726 can be positioned along a mid-plane 727 located between thefront and rear ends 704 706 of the fiber alignment device 700.

Turning to FIG. 70, a cross-sectional view of the fiber alignment device700 is depicted with the first optical fiber 720 inserted within thealignment groove structure 702. FIG. 71 is an enlarged view of a portionof FIG. 70 depicting the first angled transition surface 718 a.

The fiber alignment device 700 includes first and second angledtransition surfaces 718 a, 718 b (e.g., tapered surfaces) that areformed as part of the projections 716 a, 716 b. The first and secondangled transition surfaces 718 a, 718 b are positioned between the frontand rear ends 704, 706 of the fiber alignment device 700. The first andsecond angled transition surfaces 718 a, 718 b are each configured toface downward toward the to alignment groove structure 702. In certainexamples, the angled transition surfaces 718 a, 718 b can be angledrelative to the fiber insertion axis 610. One advantage to having theangled transition surfaces 718 a, 718 b is that the first and secondangled transition surfaces 718 a, 718 b can eliminate the need for anytransitions, tapers, or lead-ins at the end of the alignment groovestructure 702. It will be appreciated that the first and second angledtransition surfaces 718 a, 718 b are arranged and configured with thesame construction and features. For the sake of brevity, only the firstangled transition surface 718 a will be described herein with referenceto FIGS. 72-85. It will be appreciated that the same description couldalso apply to the second angled transition surface 718 b.

The fiber alignment device 700 also includes first and secondstabilization structures 734 a, 734 b (e.g., fiber stabilizationstructure) positioned at the front and rear ends 704, 706 of the fiberalignment device 700. The second housing piece 714 includes thestabilization structures 734 a, 734 b. The alignment groove structure702 and the first and second stabilization structures 734 a, 734 b eachface in an opposing direction as compared to the first and secondprojections 716 a 716 b. The stabilization structures 734 a, 734 b areelevated above the alignment groove structure 702. The stabilizationstructures 734 a, 734 b face upward away from the alignment groovestructure 702. The first angled transition surface 718 a is positionedbetween the first stabilization structure 734 a and the mid-plane 727 ofthe fiber alignment device 700 and the second angled transition surface718 b is positioned between the second stabilization structure 734 b andthe mid-plane 727 of the fiber alignment device 700. The first angledtransition surface 718 a can be positioned between contact locations 733of the stabilization structure 734 and the alignment groove structure702. The fiber insertion axis 610 intersects the first and second angledtransition surfaces 718 a, 718 b and is above the stabilizationstructures 734 a, 734 b.

In certain examples, the first and second angled transition surfaces 718a, 718 b are respectively axially positioned between the stabilizationstructures 734 a, 734 b and the alignment groove structure 702. It willbe appreciated that the first and second stabilization structures 734 a,734 b are arranged and configured with the same construction andfeatures. For the sake of brevity, only the first stabilizationstructure 734 a will be described herein with reference to FIGS. 72-85.It will be appreciated that the same description could also apply to thesecond stabilization structure 734 b.

The fiber alignment device 700 includes a fiber path for receiving anoptical fiber. The fiber path can be defined between the first andsecond housing pieces 712, 714. The fiber path includes a first fibercontact location 701 (see FIG. 70) provided by the alignment groovestructure 702, a second fiber contact location 703 (see FIG. 70)provided by a deflection structure 719 a (see FIG. 70) of the projection716 a, and a third fiber contact location 705 (see FIG. 70) provided bythe first stabilization structure 734 a. The first fiber contactlocation 701 can be spaced from the third fiber contact location 705 inan orientation along the fiber path 707. The second fiber contactlocation 703 can be positioned between the first and third fiber contactlocations 701, 705 in the orientation along the fiber path 707.

The first optical fiber 720 includes a first side 730 (see FIG. 78) andan opposite second side 732 (see FIG. 78). When the first optical fiber720 has been fully inserted along the fiber path 707: a) the first side730 of the optical fiber 720 contacts the second fiber contact location703 causing the first optical fiber 720 to be deflected such that thesecond side 732 of the first optical fiber 720 comes into contact withthe first fiber contact location 701 and the third fiber contactlocation 705; and b) the first optical fiber 720 can be flexed betweenthe first and third fiber contact locations 701, 705 by engagement withthe second fiber contact location 703. The inherent elasticity of theflexed optical fiber 720 causes an end portion 709 of the first opticalfiber 720 to be biased within the alignment groove structure 702 at thefirst fiber contact location 701.

Referring to FIGS. 72-73, a schematic view of the fiber alignment device700 is depicted with the first optical fiber 720 shown inserted thereinthrough the front end 704. The first optical fiber 720 can enterstraight therein and can be guided by the transition portions 708. Thefirst optical fiber 720 can encounter three different structures of thefiber alignment device 700 when being inserted therein. The threedifferent structures of the fiber alignment device 700 include thealignment groove structure 702, the first angled transition surface 718a, and the stabilization structure 734 a.

FIGS. 74-77 show further increments of the first optical fiber 720during a relative movement of the first optical fiber 720 through thefiber insertion opening 710 of the fiber alignment device 700. While thefirst optical fiber 720 is being inserted further through the fiberalignment device 700, the first optical fiber 720 can engage with thefirst angled transition surface 718 a. The first angled transitionsurface 718 a deflects the first optical fiber 720 to an angledorientation relative to the alignment groove structure 702 and the fiberinsertion axis 610. The first angled transition surface 718 a can bearranged and configured to angle downward toward the alignment groovestructure 702 and can be oblique relative to the fiber insertion axis610. That is, the first angled transition surface to 718 a can provide atapered lead-in to direct the first optical fiber 720 into the alignmentgroove structure 702 through the larger open top side 736 (see FIG. 64A)of the alignment groove structure 702. In certain examples, the firstangled transition surface 718 a can have a v-groove like configurationand can widen (e.g., in a funnel-like manner) as it extends away fromthe mid-plane 727 of the fiber alignment device 700 and toward the frontend 704 of the fiber alignment device 700.

While the first optical fiber 720 is inserted further into the fiberalignment device 700, the first angled transition surface 718 a causesthe first optical fiber 720 to bend downward and transition into thealignment groove structure 702. The first optical fiber 720 forms a bendportion 721 while under the stress of the first angled transitionsurface 718 a. When the first optical fiber 720 starts to bend, thefirst optical fiber 720 engages the contact locations 733 of thestabilization structure 734 a. The stabilization structure 734 a engagesthe first side 730 of the first optical fiber 720 to support the firstoptical fiber 720 when the first optical fiber 720 moves under stress ofthe first angled transition surface 718 a.

FIGS. 78-82 are schematics that show the first optical fiber 720 indiscrete positions as the first optical fiber 720 is inserted furtherinto the fiber alignment device 700.

The first optical fiber 720 has been inserted to engage the deflectionstructure 719 a (e.g., fiber deflection structure) of the projection 716a. The deflection structure 719 a engages the second side 732 of thefirst optical fiber 720 to deflect the first optical fiber 720 such thatthe first optical fiber 720 flexes into the alignment groove structure702 at an angle.

FIG. 79 depicts when the first optical fiber 720 hits contact alignmentsurfaces 724 of the alignment groove structure 702, the inherentflexibility of the first optical fiber 720 causes the first opticalfiber 720 to flex again. The contact alignment surfaces 724 of thealignment groove structure 702 face upward in the same direction as thecontact locations 733 of the stabilization structure 734 a.

The position of the deflection structure 719 a and the alignment groovestructure 702 can cause the first optical fiber 720 to be configured ina state of flex such that as the first optical fiber 720 moves furtherinto the fiber alignment device 700, the first optical fiber 720 canstart to lay down flat in the alignment groove structure 702. Thealignment groove structure 702 engages the first side 730 of the firstoptical fiber 720 when the first optical fiber 720 is positionedtherein. The bend portion 721 of the first optical fiber 720 provides aspring force to hold the first optical fiber 720 in the alignment groovestructure 702.

Referring to FIGS. 80-81, the deflection structure 719 a can create astress on the first optical fiber 720 to force the first optical fiber720 downward while the stabilization structure 734 a supports andstabilizes the first optical fiber 720 while the first optical fiber 720as the first optical fiber 720 is inserted into fiber alignment device700. The stabilization structure 734 a causes the first optical fiber720 to form a “S” curve. That is, the deflection structure 719 a and thestabilization structure 734 a are relatively positioned to cause aslight “S” bend 723 in the first optical fiber 720 between thedeflection structure 719 a and the stabilization structure 734 a.

Referring to FIG. 82, the first optical fiber 720 has elastic propertiesthat allows the first optical fiber 720 to lay flat within the alignmentgroove structure 702 and to create a flatten fiber portion 725. Theflatten fiber portion 725 can be positioned between the deflectionstructure 719 a and the mid-plane 727. The first optical fiber 720 canhit contact surfaces 724 of the fiber alignment groove 702 such that thefirst optical fiber 720 remains down and flat within the fiber alignmentgroove 702. The elasticity of the first optical fiber 720 holds thefirst optical fiber 720 within the fiber alignment groove 702. As such,there is no need for a rigid bore style or spring style alignment.

Turning again to FIG. 69, an endface 717 (see FIG. 71) of the firstangled transition surface 718 a and the contact locations 733 of thestabilization structure 734 a may overlap (e.g., the endface 717 may belocated lower than the top of the stabilization structure 734 a). Insome examples, the vertical spacing between the bottom endface 717 ofthe first angled transition surface 718 a and the top contact locations733 of the stabilization structure 734 a can be less than a diameter Dof the first optical fiber 720.

In certain examples, the fiber alignment device 700 has a length L ofabout 8 mm, although variations are possible. The point of deflection ofthe first optical fiber 720 can be within about 5 mm of the intendedcoupling location 726 (e.g., fiber to fiber interface location) of thefirst optical fiber 720, although alternatives are possible.

Various modifications and alterations of this disclosure will becomeapparent to those skilled in the art without departing from the scopeand spirit of this disclosure, and it should be understood that thescope of this disclosure is not to be unduly limited to the illustratedexamples set forth herein.

What is claimed is:
 1. An optical fiber alignment device having a frontend, an opposite rear end, and a mid-plane located between the front andrear ends, the optical fiber alignment device comprising: first andsecond housing pieces adapted to mate together; the first housing pieceincluding first and second projections with angled transition surfacesrespectively positioned between the front and rear ends of the fiberalignment device, the first and second projections respectively havingfirst and second deflection structures; the second housing pieceincluding first and second stabilization structures respectivelypositioned adjacent the front and rear ends of the fiber alignmentdevice, the second housing piece defining a groove-type alignmentstructure, the first and second stabilization structures being elevatedabove the groove-type alignment structure; wherein the first projectionis positioned between the mid-plane of the optical fiber alignmentdevice and the first stabilization structure, and the second projectionis positioned between the mid-plane of the optical fiber alignmentdevice and the second stabilization structure; first and second opticalfibers being respectively inserted through the front and rear ends ofthe optical fiber alignment device along a fiber insertion axis, ends ofthe first and second optical fibers being coupled together near themid-plane of the optical fiber alignment device; when the first andsecond optical fibers are inserted, the first and second optical fibersengage the angled transition surfaces such that the first and secondoptical fibers are flexed downward, the first and second deflectionstructures make contact with a first side of the first and secondoptical fibers, respectively, to create stress on the first and secondoptical fibers while the first and second stabilization structuresrespectively support the first and second optical fibers, the first andsecond optical fibers being configured to engage a contact alignmentsurface of the groove-type alignment structure and to lay within thegroove-type alignment structure; wherein the groove-type alignmentstructure engages a second side of the first and second optical fibers,and wherein the first and second stabilization structures also engagethe second side of the first and second optical fibers, respectively;and wherein flexure of the first and second optical fibers by the firstand second deflection structures and the first and second stabilizationstructures causes end portions of the first and second optical fibers tolay flat in the groove-type alignment structure under spring loadprovided by the flexed first and second optical fibers.
 2. The alignmentdevice of claim 1, wherein the first and second angled transitionsurfaces have a taper configuration for guiding the first and secondoptical fibers into the groove-type alignment structure.
 3. Thealignment device of claim 1, wherein the first and second angledtransition surfaces each have an oblique angle relative to the fiberinsertion axis.
 4. The alignment device of claim 1, wherein spacingbetween a respective endface of the first and second angled transitionsurfaces and respective contact locations of the first and secondstabilization structures is overlapping.
 5. The alignment device ofclaim 1, wherein spacing between a respective endface of the first andsecond angled transition surfaces and respective contact locations ofthe first and second stabilization structures is less than a diameter ofthe first and second optical fibers, respectively.
 6. The alignmentdevice of claim 1, wherein the first and second optical fibers create aS-curve within the optical fiber alignment device.
 7. A fiber alignmentdevice for receiving an optical fiber of a ferrule-less fiber opticconnector, the optical fiber including a first side and an oppositesecond side, the fiber alignment device including: a first piece thatdefines a fiber deflection structure; a second piece including agroove-type fiber alignment structure and a fiber stabilizationstructure that each face in an opposing direction as compared to thefiber deflection structure; a fiber path for receiving the opticalfiber, the fiber path being defined between the first and second pieces,wherein the fiber path includes a first fiber contact location providedby the groove-type fiber alignment structure, a second fiber contactlocation provided by the fiber deflection structure, and a third fibercontact location provided by the fiber stabilization structure, thefirst fiber contact location being spaced from the third fiber contactlocation in an orientation along the fiber path, and the second fibercontact location being positioned between the first and third fibercontact locations in the orientation along the fiber path; and whereinwhen the optical fiber has been fully inserted along the fiber path: a)the first side of the optical fiber contacts the second fiber contactlocation causing the optical fiber to be deflected such that the secondside of the optical fiber comes into contact with the first fibercontact location and the third fiber contact location; and b) theoptical fiber is flexed between the first and third fiber contactlocations by engagement with the second fiber contact location, whereinthe inherent elasticity of the flexed optical fiber causes an endportion of the optical fiber to be biased within the groove-type fiberalignment structure at the first fiber contact location.
 8. The fiberalignment device of claim 7, wherein not one of the first, second andthird fiber contact locations is provided as part of the fiber opticconnector.
 9. The fiber alignment device of claim 7, wherein the first,second and third fiber contact locations are fixed in position relativeto one another regardless of a position of the fiber optic connector.10. The fiber alignment device of claim 7, wherein the third fibercontact location is elevated relative to the first fiber contactlocation in a direction toward the first piece.
 11. The fiber alignmentdevice of claim 7, wherein when the optical fiber is inserted into thefiber path, the optical fiber does not engage the third fiber contactlocation until after the optical fiber has been deflected via contactwith the second fiber contact location.
 12. The fiber alignment deviceof claim 7, wherein the second piece is formed by an insert moldingprocess in which a single insert is used to define the groove-type fiberalignment structure, the fiber stabilization structure, and the fiberdeflection structure for engaging the first piece to ensure preciserelative positioning between the first and second pieces.
 13. The fiberalignment device of claim 7, wherein the end portion of the opticalfiber is at an angle with respect to an axis of the groove-type fiberalignment structure, the angle being less than 1 degree.
 14. The fiberalignment device of claim 7, wherein the end portion of the opticalfiber is parallel to an axis of the groove-type fiber alignmentstructure in the fiber alignment device.